Printed placemat, potholder, and oven mitt and methods for making same

ABSTRACT

Printed placemats, potholders, and oven mitts, and process for producing same using a high definition color sublimation printing technique. The sublimation printing technique applies a high quality image onto a print receiving layer that is incorporated into a printed placemat, potholder, or oven mitt. The print receiving layer can be adhesively bonded to the printed placemat, potholder, or oven mitt.

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/392,702, filed Jun. 27, 2002.

FIELD OF THE INVENTION

[0002] The present invention relates generally to a printed textile andmethod for making same, and more particularly to a printed placemat,potholder, or oven mitt and process where the printed image is obtainedby heat transfer sublimation printing techniques.

BACKGROUND OF THE INVENTION

[0003] High quality decorative kitchen textiles such as placemats,potholders oven mitts, tablecloths, and napkins are always in demand andhighly sought after for home and commercial applications. Thereproduction of sharp and durable images with extraordinary imageresolution and retention on such textile products remains a constantproblem and unmet need in the textile producing industry.

[0004] The current methods used to produce printed placemats is silkscreening. Silk screening produces a relatively poor image with lowcolor and image retention after final assembly using pre-printedfabrics. Further, the image produced by silk screening is not durableand fades when washed. Accordingly, it is highly desirable to have aprinted placemat, potholder, or oven mitt with durable and sharp imagethat is efficient and economical to produce. Until the presentinvention, it was not known to use a sublimation transfer process forplacemats, potholder, or oven mitts. The placemat, potholder, or ovenmitt of the present invention have sharp images that can withstandrepeated washings without fading.

SUMMARY OF THE INVENTION

[0005] The present invention is a printed placemat, potholder and ovenmitt, and process for producing same using a high definition colorsublimation printing technique. The sublimation printing techniqueapplies a high quality image onto a print receiving layer that isincorporated into a printed placemat, potholder, or oven mitt. The useof sublimation printing allows for better color absorption while notlimiting the amount of colors that can be used as in traditional screenprinting. The print receiving layer can be adhesively bonded to theprinted placemat, potholder, or oven mitt or attached with stitching.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] For the purpose of illustrating the invention, there is shown inthe drawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

[0007]FIG. 1 is a perspective view with cut-away that illustrates aplacemat according to one embodiment of the invention;

[0008]FIG. 2 is a perspective view with cut-away that illustrates apotholder according to one embodiment of the invention;

[0009]FIG. 3 is a perspective view that illustrates a pocket potholderaccording to one embodiment of the invention;

[0010]FIG. 4 illustrates a full print oven mitt according to oneembodiment of the invention; and

[0011]FIG. 5 is a perspective view that illustrates a cuff print ovenmitt according to one embodiment of the invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0012] The present inventions provide printed placemats, potholders, andoven mitts constructed in a manner that allows them to be printed usinga high definition color sublimation printing technique. The printedplacemats, potholders, and oven mitts have a print receiving layerattached to the article by mechanical or chemical means, such as but notlimited to, stitching and/or an adhesive layer.

[0013] A blank print receiving layer is treated with heat and pressuresufficient to fix (also referred to as preshrink) the material. Althoughit is preferred that the material be preshrunk prior to, or at the timeof, final fabrication, it is understood that it can also be preshrunkbefore, during or after final fabrication. To achieve high resolutionfrom the image transfer process and to achieve uniformity in shape ofthe final product, heat and pressure are applied to the print receivinglayer prior to or at the time of the image transfer process. Printing onthe print receiving layer is applied using a sublimation printingprocess employing image transfer from a dye sheet by means of heat andpressure.

[0014]FIG. 1 shows an exemplary printed placemat 10 with a cut away toillustrate the placemat's construction. As shown in FIG. 1, the placemat10 is composed of two pieces of fabric. The first fabric is the printreceiving piece or layer 16. The print receiving layer 16 is preferablycomposed of a single-ply non-absorbent material selected from the groupconsisting of polyester, nylon, and acrylic, or some combinationthereof. In certain embodiments, the print receiving layer 16 iscomposed of 100% polyester. It is understood, however, that fabricscontaining less than 100% polyester may also be used.

[0015] The second piece of fabric is the body or backing layer 12 of theplacemat 10 and is preferably composed of a polyester and cotton blend.In certain preferred embodiments, a 50% polyester/50% cotton blend isused to form the backing layer 12. It is understood, however, thatfabrics containing some other blend of natural and synthetic fibers canalso be used. Further, the material used for the backing layer 12 cancomprise 100% natural or synthetic fibers.

[0016] The print receiving layer 16 and backing layer 12 can be treatedwith a combination of resins to form an adhesive layer 14 that is usedto assemble and secure the print receiving layer 16 and backing layer 12to each other. An adhesive layer 14 that covers the majority of the topface of the backing layer 12 and the lower bottom face of the printreceiving layer 16 can be used to improve the stiffness and shaperetention of the printed placemat 10. As such, the printed placement 10will lie flat and not wrinkle.

[0017] In certain embodiments, two types of resins are used incombination, one is a low temperature resin to secure the two fabricsinto a working assembly, and the second is a high temperature resin topermanently secure the fabrics when the image is transferred to theprint receiving layer 16. The composition of resins is between 10 to 40%low temperature resin and 60 to 90% high temperature resin. The ratio oflow temperature resin to high temperature resin can be varied dependingon the amount of retention desired in the initial heating stage.

[0018] In certain embodiments, the low temperature resin is acopolyester adhesive made by EMS-CHEMIE Inc. known as Griltex® 9 and thehigher temperature resin is a copolyester adhesive made by EMS-CHEMIEInc. known as Griltex® D 1377E. The resins can be applied by means of aroll glue coating machine, such as that made by 2M in Quebec Canada.Other application machines, known to those skilled in the art, can alsobe used to apply the resins. Alternatively, the resins can be applied tothe fabrics in powder form by dusting or by spray or soaking in liquidform.

[0019] After the resins are applied, the print receiving layer 16 andbacking layer 12 are cut to size and placed adjacent to one another. Incertain embodiments, a stitching 18 is used to help maintain properalignment and bonding between the print receiving layer 16 and backinglayer 12. An initial amount of heat and pressure is applied to theplacemat 10 to form a bond between the print receiving layer 16 andbacking layer 12. A transfer dye containing a desired image is placedonto the print receiving layer 16 and the image is transferred to theplacemat using sublimation printing techniques. A final amount of heatand pressure is applied to the placemat 10 to transfer the image of atransfer dye onto the print receiving layer 16. In addition totransferring the image to the print receiving layer 16, the applicationof heat and pressure makes the adhesion between the print receivinglayer 16 and backing layer 12 more permanent.

[0020] In one embodiment, the print receiving layer 16 and backing layer12 are placed through a roll glue coating machine where the resins areapplied to the fabrics. The print receiving layer 16 and backing layer12 are placed together and passed through an initial heat and pressureprocess of 375-425 degrees F., for 10-20 seconds, at 60-80 PSI. Atransfer dye containing a desired image is placed onto the printreceiving layer 16 and the image is transferred to the placemat usingsublimation printing techniques.

[0021] In another embodiment, the perimeter edges of the print receivinglayer 16 and backing layer 12 are folded over after the resins areapplied. Folding over the edges of the print receiving layer 16 andbacking layer 12 prevents the resin from being exposed at the edge ofthe placemat 10 and creates a more appealing edge. The resin is used tokeep the edges folded. The print receiving layer 16 and backing layer 12are placed together. Stitching 18 is used around the perimeter tocombine the print receiving layer 16 and backing layer 12 where theresin is covered by the fold. The placemat 10 is passed through aninitial heat and pressure process of 375-425 degrees F., for 10-20seconds, at 60-80 PSI. A transfer dye containing a desired image isplaced onto the print receiving layer 16 and the image is transferred tothe placemat using sublimation printing techniques. The image covers thestitching 18 and makes the stitching 18 inconspicuous.

[0022] In another embodiment, the perimeter edges of the print receivinglayer 16 and backing layer 12 cut and not folded. The resins can beapplied before or after cutting. Heat may accompany the cutting processsuch that the cut edges are crimped to prevent unraveling.

[0023]FIG. 2 shows an exemplary printed potholder 20 with a cut away toillustrate the potholder's construction. As shown in FIG. 2, the printedpotholder 20 has a backing layer 22 and a print receiving layer 24. Theprint receiving layer 24 is preferably composed of a single-plynon-absorbent material selected from the group consisting of polyester,nylon, acrylic, or some combination thereof. In certain embodiments, theprint receiving layer 16 is composed of 100% polyester. It isunderstood, however, that fabrics containing less than 100% polyestermay also be used.

[0024] The second piece of fabric is the body or backing layer 22 of theprinted potholder 20 and is preferably composed of a polyester andcotton blend. In preferred embodiments, the backing layer 22 is aquilted heat resistant fabric. In certain embodiments, a 50%polyester/50% cotton blend is used to form the backing layer 22. It isunderstood, however, that fabrics containing 100% natural, 100%synthetic, or some other blend of natural and synthetic fibers can alsobe used. Further, the backing layer 22 may comprise several layers ofmaterial, including a woven decorative outer layer and athree-dimensional non-woven inner layer.

[0025] The potholder 20 can be assembled using an adhesive layer in asimilar fashion to that described for the printed placement 10.Alternatively, the print receiving layer 24 can be attached to thebacking layer 22 with stitching 28. Binding 26 can be used along withthe stitching 28 to cover unfinished edges and improve the potholder'sappearance. In preferred embodiments, the print receiving layer 24 isprinted prior to assembling the potholder 20 and is attached to thepotholder 20 with stitching 28.

[0026] In one embodiment, a printed potholder is produced that has aprint receiving layer 24 made from a single-ply polyester fabric sheet.The print receiving layer 24 is cut and pre-shrunk by the application ofa heat process of 375-425 degrees for 10-20 seconds at 60-80 psi. Animage is then applied to the print receiving layer 24 by sublimationprinting. The printed receiving layer 24 is cut to be congruent andconform with the shape of the backing layer 22. The backing layer 22 iscomprised of a layer of heat resistant woven fabric on the face oppositethe print receiving layer 24 and a layer of quilted heat resistantnon-woven materials between the woven fabric and print receiving layer24. The print receiving layer 24 and backing layer 22 are joined andbinding 26 is placed around the perimeter. Stitching 28 is then appliedto the potholder 20 proximate the binding 26 to join the binding 26,print receiving layer 24, and backing layer 22.

[0027]FIG. 3 shows a printed potholder with pocket 30. As shown in FIG.3, the print receiving layer 34 does not cover the backing layer 22completely. The printed potholder with pocket 30 is assembled in asimilar manner to that described for printed potholder 20, shown anddescribed as FIG. 2, except that pocket binding 40 is used to form anentrance to a pocket between the print receiving layer 34 and thebacking layer 22. As such, a user may place his or her hand between theprint receiving layer 34 and backing layer 22 to assist in handling thepotholder. Also shown in FIG. 3, is a loop 42 created from binding 36and stitching 38 for hanging the printed potholder with pocket 30 whennot in use.

[0028]FIG. 4 shows a full print oven mitt 50. As shown in FIG. 4, theoven mitt is assembled in a similar manner to printed potholder 20. Theoven mitt 50 has a print receiving layer 54 and a backing layer 52.Unlike the potholder 20, the oven mitt 50 has a third layer 53 oppositethe backing layer 52 to form a mitt. The mitt forming or third layer 53can be made from the same materials used for the backing layer 52.

[0029] In one embodiment, an oven mitt is produced that has a printreceiving layer 54 made from a single-ply polyester fabric sheet. Theprint receiving layer 54 is cut and pre-shrunk by the application of aheat process of 375-425 degrees for 10-20 seconds at 60-80 psi. An imageis then applied to the print receiving layer 54 by sublimation printing.A backing layer 52 and a third layer 53 are cut from a heat resistantmaterial. The heat resistant material can be a batting between non-wovenmaterials. The backing layer 52 and third layer 53 form mirror images ofeach other. The printed receiving layer 54 is cut to be congruent andconform with the shape of the backing layer 52. The print receivinglayer 54, backing layer 52, and third layer 53 are joined around theperimeter by stitching 58. Binding 56 is attached at the oven mitt 50opening.

[0030]FIG. 5 shows a cuff print oven mitt 60. As shown in FIG. 5, theoven mitt is assembled in a similar manner to the full print oven mitt50. The oven mitt 60 has a print receiving layer 64, a backing layer 62,a third layer 63, binding 66, and a seam 68. Unlike the full print ovenmitt 50, however, the print receiving layer 64 of the cuff print ovenmitt 60 only covers a portion of the backing layer 62.

[0031] These and other advantages of the present invention will beapparent to those skilled in the art from the foregoing specification.Accordingly, it will be recognized by those skilled in the art thatchanges or modifications may be made to the above-described embodimentswithout departing from the broad inventive concepts of the inventions.It should therefore be understood that the inventions are not limited tothe particular embodiments described herein, but are intended to includeall changes and modifications that are within the scope and spirit ofthe inventions as set forth in the claims.

What is claimed:
 1. A printed placemat, comprising: a placemat body, anda conformal print receiving layer attached to said placemat body, saidprint receiving layer composed of non-absorbent material selected fromthe group consisting of polyester, nylon, acrylic or combinationsthereof, wherein printing is applied to the print receiving layer usinga sublimation printing process.
 2. The printed placemat of claim 1,wherein said print receiving layer is pre-shrunk prior to said printing.3. The printed placemat of claim 2, wherein said print receiving layeris pre-shrunk immediately before said printing.
 4. The printed placematof claim 1, wherein the print receiving layer is pre-shrunk concurrentlywith the application of the sublimation printing process.
 5. The printedplacemat of claim 1, wherein said print receiving layer is polyester. 6.The printed placemat of claim 1, further comprising an adhesive layerdisposed between said print receiving layer and said placemat body. 7.The printed placemat of claim 6, wherein said adhesive layer comprises alow temperature resin and a high temperature resin.
 8. A method ofmaking a printed placemat, comprising the steps of: applying an adhesiveresin to a first sheet of fabric; applying an adhesive resin to a secondsheet of fabric; bonding said first sheet of fabric to said second sheetof fabric using an initial amount of heat and pressure; and applying asecond amount of heat and pressure to said first sheet of fabric totransfer an image from a transfer dye onto said first sheet of fabricusing a sublimation printing process.
 9. The method of claim 8, whereinsaid first sheet of fabric is selected from the group consisting ofpolyester, nylon, acrylic or combinations thereof.
 10. The method ofclaim 9, wherein said first sheet of fabric is polyester.
 11. A printedpotholder, comprising: a backing layer; and a conformal print receivinglayer attached to said backing layer, said print receiving layercomposed of non-absorbent material selected from the group consisting ofpolyester, nylon, acrylic or combinations thereof, wherein printing isapplied to the print receiving layer using a sublimation printingprocess.
 12. The printed potholder of claim 11, wherein said printreceiving layer is pre-shrunk prior to said printing.
 13. The printedpotholder of claim 11, wherein said print receiving layer is pre-shrunkconcurrently with said printing.
 14. The printed potholder of claim 11,wherein a pocket is formed between said print receiving layer and saidbacking layer.
 15. The printed potholder of claim 14, wherein said printreceiving layer covers less than all of said backing layer.
 16. Theprinted potholder of claim 11, wherein said print receiving layer ispolyester.
 17. The printed potholder of claim 11, further comprising anadhesive layer disposed between said print receiving layer and saidpotholder body.
 18. A method of making a printed potholder, comprisingthe steps of: applying an adhesive resin to a backing layer; applying anadhesive resin to a print receiving layer; bonding said print receivinglayer to said backing layer using an initial amount of heat andpressure; and applying a second amount of heat and pressure to saidprint receiving layer to said backing layer to transfer an image from atransfer dye onto said print receiving layer using a sublimationprinting process.
 19. The method of claim 18, wherein said printreceiving layer is selected from the group consisting of polyester,nylon, acrylic or combinations thereof.
 20. The method of claim 19,wherein said print receiving layer is polyester.
 21. A printed ovenmitt, comprising: a backing layer; a conformal print receiving layerattached to said backing layer, said print receiving layer composed ofnon-absorbent material selected from the group consisting of polyester,nylon, acrylic or combinations thereof, wherein printing is applied tothe print receiving layer using a sublimation printing process; and amitt forming layer.
 22. The printed oven mitt of claim 21, wherein saidprint receiving layer is pre-shrunk prior to said printing.
 23. Theprinted oven mitt of claim 21, wherein said print receiving layer ispre-shrunk concurrently said printing.
 24. The printed oven mitt ofclaim 21, wherein said print receiving layer covers less than all ofsaid backing layer.
 25. The printed oven mitt of claim 21, wherein saidprint receiving layer is polyester.
 26. The printed oven mitt of claim21, further comprising an adhesive layer disposed between said printreceiving layer and said backing layer.
 27. A method of making a printedoven mitt, comprising the steps of: applying an adhesive resin to abacking layer; applying an adhesive resin to a print receiving layer;bonding said print receiving layer to said backing layer using aninitial amount of heat and pressure; applying a second amount of heatand pressure to said print receiving layer to transfer an image from atransfer dye onto said print receiving layer using a sublimationprinting process; and attaching said print receiving layer and saidbacking layer to a mitt forming layer.
 28. The method of claim 27,wherein said print receiving layer is selected from the group consistingof polyester, nylon, acrylic or combinations thereof.
 29. The method ofclaim 28, wherein said print receiving layer is polyester.